The first stage of the automation project began full production in early 2025 and aims to boost sheet metal productivity in the plant in Worcester, whilst also providing a real-life showroom for the company’s laser and automation systems.
Central to the upgrade has been the introduction of two new 6 kW OPTIPLEX 3015 NEO 2D Fiber laser machines used to cut a variety of components for its range of UK-made machine tools. Mazak is the only UK-based machine tool manufacturer that uses its own machines during the production process.
The OPTIPLEX machines boast a range of productivity enhancing features, including Mazak Beam Shaping Technology and Beam Diameter Control, which delivers substantial productivity improvements and superior cutting quality whilst dramatically reducing cycle-times and improving productivity by up to 40 per cent.
By adjusting the beam shape, operators are now able to cut material up to 50mm with four times more stability compared to conventional cutting. Adjusting the beam shape can also improve the bevel angle by more than 80 per cent versus conventional machines, significantly increasing the accuracy of the cut.
The two new machines replaced three older Hyper gear 510s and one NTX-48 CO2 laser cutting machine. The new fiber lasers are tended by a Mazak CSTD Double Tower system to feed the sheet metal and a robotised Mazak Smart Manufacturing Cell for parts sorting. The double towers have sufficient storage for materials and scrap and have multiple conveying units to reduce machine waiting times and further improve productivity through unmanned operations.
The upgrade to the sheet metal cutting capability will help the plant achieve its environmental and sustainable manufacturing objectives. The introduction of the two OPTIPLEX NEO machines will reduce power consumption by 67 per cent compared to the four CO2 machines previously employed – ultimately helping the Worcester facility reduce its overall carbon footprint, the company said.
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Richard Smith, European Group Managing Director at Yamazaki Mazak, commented: “Mazak’s philosophy has always been to invest in new technology to achieve productivity improvements and reduce cost. We have replaced four machines with two while shortening cycle times, improving throughput in the factory and making our sheet metal operations much more efficient.
“The improvements are ultimately designed to benefit our own customers by reducing lead times on our key UK-built machines whilst also supporting our sustainability commitments and our focus on environmentally friendly manufacturing.”
Mazak’s new Sheet Metal Department will be open to visitors at the company’s upcoming European Laser Event, which will be held at its European Manufacturing Plant in Worcester on May 20-22, 2025.
In addition to the two new 6 kW OPTIPLEX 3015 NEO 2D Fiber laser machines, which will be live-cutting in the factory, the event will give laser customers from across Europe the opportunity to experience a demonstration of its TUBE FT-150 NEO laser processing machine. Ideally suited for automatic material loading, laser cutting, drilling and unloading, its unique U-axis provides uninterrupted high-speed, high-quality cutting of small and medium diameter tubes.
In addition, the company's new European site boasts an enhanced user experience tailored to meet the diverse needs of its customer base, underpinned by a responsive and contemporary layout optimised for mobile, tablet, and desktop.
Users benefit from simplified navigation and quick access to Mazak’s most frequently accessed sections, including product catalogues, technical specifications, support services and contact information for representatives throughout the organisation’s broad network.
